JP2015082938A - Non-flat plate-like coil manufacturing device and non-flat plate-like coil manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To quickly mass-produce non-flat plate-like coils having a uniform shape.SOLUTION: A non-flat plate-like coil manufacturing device 20 comprises: a wire feeding machine 50 for feeding a wire 11 on the outer peripheral surface of which a fusion layer is formed at constant tension; a take-up device 21 for winding the wire 11 fed from the wire feeding machine around a circumference of a winding core 22 to obtain a flat coil 12; heating means 71 for fusing or softening the fusion layer by heating the wire wound around the winding core; a molding die 73 for molding the flat coil by pressing the flat coil; moving means 78 for moving the molding die between a molding position at which the molding die is positioned at an edge of the winding core and a stand-by position away from the edge of the winding core 22; and coil extraction molding means 90 for extracting the flat coil 12 made of the wire 11 wound around the winding core 22 from the winding core 22 and pressing it to the molding die 73 at the molding position. An engaged part 22d is formed at the edge of the winding core 22, and an engaging part 73b that can be engaged with the engaged part 22d at the molding position is formed on the molding die 73.

Description

  The present invention relates to a non-plate coil manufacturing apparatus and a non-plate coil manufacturing method for manufacturing a non-plate coil such as a saddle used in a motor or the like.

  Conventionally, as a method of manufacturing a coil having a non-flat shape such as a saddle type, a flat coil formed using a winding die is pressed at a time using a press die composed of a lower die and an upper die. A method has been proposed (for example, see Patent Document 1).

  The non-plate-like coil obtained by this manufacturing method has a pair of linear portions facing each other with a predetermined interval, and an arc portion connecting the ends of the pair of linear portions in an arc shape. It is said that it is a mold coil, and after winding using an adhesive copper wire having a fusion layer formed on the outer peripheral surface, the copper wire is energized to join the copper wires to obtain a flat coil first. After that, the flat coil thus obtained is press-molded. In the press molding, the copper wire is energized again to melt or soften the fusion layer again, and press molding is performed in that state.

Japanese Patent Publication No.58-32450

  However, in the coil manufacturing method in Patent Document 1, the winding of the flat coil and the press molding are performed in separate processes, and the fusion layer is melted or softened separately for each process. It has been broken. As described above, the fusion layer is melted or softened several times. As a result, it takes a certain amount of time to obtain a non-flat coil having a desired shape, and the non-flat coil is manufactured relatively quickly. There was a problem that made it difficult to do.

  In order to eliminate this point, it is conceivable to press-mold without melting or softening the fusion layer. However, when press-molding a flat coil in which adjacent wires contacting each other are fixed to each other, Sticking is broken. For this reason, even if the non-flat coil is obtained by press-molding without melting or softening the fusion layer, the wires constituting the non-flat coil are separated from each other, and the shape cannot be maintained. Let

  In the coil manufacturing method in Patent Document 1, a flat coil previously obtained by winding is once removed from the winding core, and then newly installed in a press device and press-molded. For this reason, if a positional shift occurs when the flat coil is installed in the press apparatus, it becomes difficult to obtain a non-flat coil having a desired shape. For this reason, in the press molding, it is necessary to pay close attention so as not to cause the displacement of the flat coil, and there is also a problem that a rapid operation in the press molding becomes difficult.

  The objective of this invention is providing the manufacturing method of the non-plate-shaped coil which can manufacture a non-plate-shaped coil comparatively rapidly, and the manufacturing method of a non-plate-shaped coil.

  Another object of the present invention is to provide a non-plate coil manufacturing apparatus and a non-plate coil manufacturing method capable of mass-producing non-plate coils having a uniform shape.

  The apparatus for producing a non-flat coil according to the present invention includes a wire rod feeding machine that feeds a wire rod having a fusion layer formed on the outer peripheral surface thereof with a constant tension, and a wire rod fed from the wire rod feeder is wound around a core. A winding device that rotates to obtain a flat coil and heating means that heats the wire wound around the core and melts or softens the fusion layer.

  The characteristic configuration is that the flat coil is formed by pressing the flat coil, and the mold is moved between a molding position located at the edge of the core and a standby position spaced from the edge of the core. A moving means and a coil extracting and forming means for extracting a flat coil made of a wire wound around the winding core from the winding core and pressing it against a forming die at a forming position are provided.

  In this case, it is preferable that the engaged portion is formed on the edge of the winding core, and the engaging portion that can be engaged with the engaged portion at the molding position is formed on the mold.

  The method for producing a non-flat coil according to the present invention is characterized in that a wire having a fusion layer formed on its outer peripheral surface is wound around a winding core while being heated, and the obtained flat coil is formed before cooling.

  In this case, it is preferable that the flat coil is formed by positioning the forming die at the edge of the core, extracting the flat coil from the core, and simultaneously pressing the coil.

  In the non-flat coil manufacturing apparatus and non-flat coil manufacturing method of the present invention, heating means for heating the wire wound around the winding core to melt or soften the fused layer, and winding around the winding core. Coil coil forming means for extracting a flat coil made of a wire rod from the core and pressing it against a molding die at a molding position, so that the flat coil obtained by winding on the core while heating is molded before cooling. Thus, the time for obtaining a non-flat coil having a desired shape can be remarkably shortened as compared with the conventional method in which the fusion layer is melted or softened in each step of winding and forming.

  And the non-plate-like coil which formed the desired shape obtained by the shaping | molding completes the adhering between each wire, when cooling is completed after shaping | molding. For this reason, each wire which comprises the non-plate-shaped coil obtained by shaping | molding mutually adheres, and the shape of the obtained non-plate-shaped coil is maintained reliably. As a result, in the non-flat coil manufacturing apparatus and non-flat coil manufacturing method of the present invention, the non-flat coil can be manufactured relatively quickly.

  In addition, since the flat coil formed by positioning the mold at the edge of the core and pressing the flat coil extracted from the core as it is is formed into a flat coil, the position of the mold relative to the core is always constant. Thus, it is possible to prevent the positional deviation of the flat coil with respect to the mold during the molding. In particular, if the engaged portion is formed on the edge of the core and the engaging portion that can be engaged with the engaged portion is formed in the molding die at the molding position, the position of the molding die relative to the core at the molding position is It will definitely be constant. Then, the non-flat coil obtained by the molding always has a desired shape, and it becomes possible to mass-produce non-flat coils having a uniform shape.

It is a top view which shows the manufacturing apparatus of the non-flat coil of embodiment of this invention. FIG. 2 is a plan view corresponding to FIG. 1 showing a state in which the end of the core is brought into contact with the first rotating body with the molding die as a standby position. FIG. 2 is a plan view corresponding to FIG. 1 showing a state where the winding core is separated from the first rotating body and the forming die is positioned at the end edge of the winding core. It is the sectional view on the AA line of FIG. It is the BB sectional view taken on the line of FIG. FIG. 2 is an enlarged view of a wire feeding machine viewed from the direction D in FIG. 1. It is CC sectional view taken on the line of FIG. 1 which shows a winding apparatus. It is a perspective view which shows the 1st rotary body. It is a perspective view which shows the 2nd rotary body containing the winding core. It is a perspective view which shows the shaping | molding die. It is a perspective view which shows the core. It is a perspective view which shows the state by which the wire was wound around the winding core once. It is a perspective view corresponding to FIG. 12 which shows the state by which the wire was wound around the winding core, and the flat coil was obtained. FIG. 14 is a perspective view corresponding to FIG. 13 showing a state in which a forming die is positioned on the edge of the core. It is a perspective view corresponding to FIG. 14 which shows the state by which the flat coil was pressed on the shaping | molding die. It is a perspective view which shows the state from which a flat coil is shape | molded and a non-plate-like coil is obtained.

  Next, the best mode for carrying out the present invention will be described with reference to the drawings.

  FIG. 16B shows a non-flat coil 10 obtained by the manufacturing apparatus and manufacturing method of this embodiment. The non-flat coil 10 includes a pair of linear portions 10a and 10a facing each other with a predetermined interval, and arc portions 10b and 10b that connect ends of the pair of linear portions 10a and 10a in an arc shape. Is a so-called saddle coil 10. The wire 11 constituting the non-flat coil 10 uses a self-bonding wire (so-called cement wire) having a circular cross section and a fusion layer that is fused by hot air or a solvent on the outer surface. The Therefore, the adjacent wire rods 11 forming the non-circular coil 10 are in contact with each other, and the contacted wire rods 11 are fixed to each other by the fusion layer, thereby maintaining the shape of the non-flat coil 10. Shall be.

  A non-flat coil manufacturing apparatus 20 of the present invention for manufacturing such a non-flat coil 10 is shown in FIGS. Here, three axes X, Y, and Z orthogonal to each other are set, the X axis extends in a substantially horizontal front-rear direction, the Y axis extends in a substantially horizontal lateral direction, and the Z axis extends in a substantially vertical direction. The configuration of the manufacturing apparatus 20 will be described.

  The non-flat coil manufacturing apparatus 20 of the present invention includes a winding device 21 provided on a gantry 19. The winding device 21 includes a winding core 22 that actually winds the wire 11, a second rotating body 24 provided so that the winding core 22 can protrude and retract from one end face, and an end face of the second rotating body 24. A first rotating body 23 whose end face is in contact with the protruding end of the protruding winding core 22 is provided. The first rotating body 23 whose one end surface is in contact with the protruding end of the core 22 is formed in a cylindrical shape, and a flange portion 23b is formed around the one end surface. A first rotating shaft 23 a is coaxially provided on the other end surface of the first rotating body 23.

  As shown in FIG. 1 to FIG. 3 and FIG. 7, a first support wall 26 is erected on the gantry 19, and the first rotation shaft 23 a extends in the Y-axis direction and is rotatably provided on the first support wall 26. It is done. A servo motor 27 that rotates the first rotating shaft 23 a together with the first rotating body 23 is attached to the first support wall 26. Pulleys 28a and 28b are provided on the first rotating shaft 23a and the rotating shaft 27a of the servomotor 27, respectively, and a belt 28c is installed on these pulleys 28a and 28b. Thus, when the servo motor 27 is driven and the rotation shaft 27a rotates, the rotation is transmitted to the first rotation shaft 23a via the belt 28c, whereby the first rotation shaft 23a is rotated together with the first rotation body 23. Configured to let

  As shown in FIG. 8, a first protruding rod 29 is provided on the first rotating body 23 so as to be able to protrude and retract from the flange portion 23 b side. The first protruding rod 29 is a rod-shaped member protruding from the first rotating body 23 toward the core 22 (FIG. 1). In this embodiment, the four first protruding rods 29 are arranged in the axial direction. Operation rings 23 c and 23 d are provided on the outer periphery of the first rotating body 23 so that the four first protruding rods 29 protrude toward the core 22. The operation rings 23c and 23d rotate together with the first rotating body 23, and a pair of operation rings 23c and 23d are provided at a predetermined interval in the Y-axis direction. The operation roller 23e for moving the pair of operation rings 23c and 23d in the Y-axis direction is provided between the pair of operation rings 23c and 23d. By moving the operation roller 23e in the Y-axis direction, an operation ring is provided. The pair of operation rings 23c and 23d are configured to be movable in the Y-axis direction while allowing the rotation of 23c and 23d.

  As shown in FIGS. 4 and 7, a first mobile unit 31 that moves the operation rings 23 c and 23 d (FIG. 8) in the Y-axis direction is provided on the upper portion of the first support wall 26. The first mobile unit 31 is a first fluid pressure cylinder 31 that is fixed to the upper portion of the first support wall 26 by extending a protrusion / retraction rod 31a (FIG. 7) in the Y-axis direction. A first operating piece 32 is provided on the retracting rod 31a of the first fluid pressure cylinder 31, and the operating roller 23e that has entered between the pair of operating rings 23c and 23d is pivotally supported on the first operating piece 32. The

  For this reason, when the rod 31a of the first fluid pressure cylinder 31 protrudes and the first operating piece 32 is moved in the Y-axis direction, the operating roller 23e moves the operating rings 23c and 23d in the direction of the second rotating body 24. When the first protruding rod 29 (FIG. 8) is protruded from the end edge of the first rotating body 23 and the rod 31a is retracted and the first operating piece 32 is returned, the operating rings 23c and 23d move in the opposite direction. Then, as shown in FIG. 8, the protruding end of the first protruding rod 29 is configured to be flush with the end surface of the first rotating body 23.

  Returning to FIG. 1, the second rotating body 24 is formed in a columnar shape having an outer diameter substantially equal to the outer diameter of the flange portion 23 b in the first rotating body 23, and the core 22 is provided on one end side thereof. As shown in FIG. 11, the winding core 22 provided in the second rotating body 24 has a main body portion 22a and a cylindrical portion 22b, and the main body portion 22a is parallel to each other and protrudes from the end surface of the second rotating body 24. A pair of ridges 22c, 22c is formed (FIG. 9).

  Further, the core 22 is formed with an engaged portion to which an engaging portion of a molding die 73 described later can be engaged. In this embodiment, the concave line formed between the pair of convex lines 22c, 22c of the winding core 22 forms the engaged portion 22d.

  As shown in FIG. 12, a square hole 24 b approximately equal to the outer diameter of the main body portion 22 a of the core 22 is formed in the center from one end face of the second rotating body 24 along the center axis. Are accommodated in the second rotating body 24 so that the pair of ridges 22c, 22c protrude from one end face of the second rotating body 24 from the square hole 24b. The outer diameters of the first and second rotating bodies 23 and 24 are formed so as to be larger than the long pieces of the pair of ridges 22 c and 22 c constituting the core 22.

  As shown in FIGS. 12 and 13, the winding core 22 is configured to wind the wire 11 around a pair of ridges 22 c and 22 c constituting the winding core 22. An entanglement pin 24c is provided on which the winding start of the wire 11 wound around the winding core 22 is entangled. And the winding core 22 which protrudes from one end surface of the 2nd rotary body 24 is for winding up the wire 11, and forming the flat coil 12 (FIG. 13), The outer diameter is trying to obtain. It is formed equal to the inner diameter of the coil 12.

  Specifically, in this embodiment, as shown in FIG. 16B, a pair of linear portions 10a, 10a and an arc connecting the edges of the pair of linear portions 10a, 10a in an arc shape. Since it aims at obtaining the saddle type coil 10 which has the part 10b, 10b, as shown in FIG. 11, the length L1 of a pair of protrusion 22c, 22c is the length T (FIG. 16) of a pair of linear part. ), And the distance between the pair of ridges 22c and 22c is substantially equal to the inner dimension W constituting the arc portions 10b and 10b (FIG. 16) in the outer dimension D. The inner dimension of the flat coil 12 obtained by winding the wire 11 around the winding core 22 is, as shown in FIG. 16A, a long side 12a having the same length T as the straight portion 10a, A rectangular shape having a short side 12b equal to the length W of the arc portion 10b is formed.

  Returning to FIG. 1, the second rotating shaft 24 a is coaxially provided on the other end surface of the second rotating body 24. Further, as shown in FIGS. 5 and 7, the gantry 19 has second and third support walls 36, 37 on the gantry 19 at a predetermined distance from the first support wall 26 in the Y-axis direction. The second rotating shaft 24a is installed on the second and third support walls 36 and 37 so as to extend coaxially with the first rotating shaft 23a in the Y-axis direction and move in the longitudinal direction. A servo motor 38 that rotates the second rotary shaft 24 a together with the second rotary body 24 is attached to the third support wall 37.

  Pulleys 39a and 39b are provided on the second rotary shaft 24a and the rotary shaft 38a of the servo motor 38, respectively, and a belt 39c is installed on these pulleys 39a and 39b. The pulley 39 b provided on the second rotary shaft 24 a is movable in the longitudinal direction of the second rotary shaft 24 a and is provided on the third support wall 37. As a result, when the servo motor 38 is driven and the rotation shaft 38a rotates, the rotation is transmitted to the second rotation shaft 24a via the belt 39c, whereby the second rotating body 24 is configured to be rotatable.

  Further, the winding device 21 is provided with a variable interval mechanism 41 that moves the second rotating body 24 in the axial direction with respect to the first rotating body 23.

  The distance varying mechanism 41 in this embodiment includes a ball screw 42 installed on the second and third support walls 36 and 37 so as to be parallel to the second rotation shaft 24a, and a servo motor 43 that rotates the ball screw 42. , And a movable base 44 that is engaged with the ball screw 42 and moves in the Y-axis direction.

  The second rotary shaft 24a is attached to the movable table 44 so as not to move in the axial direction and to be rotatable. As a result, when the servo motor 43 is driven to rotate the ball screw 42 and the movable table 44 moves in the Y-axis direction, the second rotating shaft 24a also moves in the Y-axis direction together with the movable table 44. When the second rotating shaft 24a moves in the Y-axis direction, which is the axial direction thereof, the second rotating body 24 provided coaxially at the edge of the second rotating shaft 24a is also moved in the Y-axis direction. The

  And since the 1st rotary body 23 does not move, as shown in FIG. 13, the 2nd rotary body 24 is brought close to the 1st rotary body 23, and the protrusion of the core 22 which protrudes from the one end edge of the 2nd rotary body 24 The end is brought into contact with the end surface of the first rotating body 23 to narrow the interval between the first and second rotating bodies 23 and 24, and in this state, the first and second rotating bodies 23 and 24 are moved together with the winding core 22. When the wire 11 is wound around the winding core 22 by synchronously rotating, the wire 11 wound around the winding core 22 is sequentially successively in the gap between the first and second rotating bodies 23 and 24 in the radial direction. It is configured to be wound and thereby obtain a flat flat coil 12.

  On the other hand, as shown in FIG. 1, when the distance between the first and second rotating bodies 23 and 24 is increased by moving the second rotating body 24 away from the non-moving first rotating body 23, FIG. As shown, a molding die 73 to be described later is configured to be able to enter between them.

  As shown in FIG. 1 to FIG. 3 and FIG. 6, a wire rod feeding machine 50 that feeds the wire rod 11 is provided on the gantry 19. The wire feeding machine 50 includes a nozzle 51 through which the wire 11 is inserted, a nozzle moving mechanism 52 that moves the nozzle 51 in three axial directions, and a tension device 53 that applies tension to the wire 11.

  The nozzle 51 is fixed to the support plate 54, and the nozzle moving mechanism 52 is configured to be able to move the support plate 54 with respect to the gantry 19 in three axial directions. The nozzle moving mechanism 52 in this embodiment is configured by a combination of X-axis, Y-axis, and Z-axis direction extendable actuators 56 to 58.

  In this embodiment, a support plate 54 provided with a nozzle 51 is attached to a housing 56d of an X-axis direction extendable actuator 56 so as to be movable in the X-axis direction, and the support plate 54 is attached together with the X-axis direction extendable actuator 56 in the Z-axis direction. The follower 56c of the X-axis direction expansion / contraction actuator 56 is attached to the follower 57c of the Z-axis direction expansion / contraction actuator 57. The support plate 54 can be moved in the Y-axis direction together with the X-axis and Y-axis expansion / contraction actuators 56, 57, and the housing 57 d of the Z-axis expansion / contraction actuator 57 serves as a follower 58 c of the Y-axis expansion / contraction actuator 58. Mounted. The housing 58 d of the Y-axis direction extendable actuator 58 extends in the Y-axis direction and is fixed to the gantry 19.

  The followers 56c to 58c in the respective telescopic actuators 56 to 58 are configured to be movable by the rotation of the ball screws 56b to 58b, and the servo motors 56a to 58a for rotating the ball screws 56b to 58b are shown in the figure for controlling them. Not connected to the control output of the controller.

  As shown in FIG. 6, the support plate 54 has a cutter device 59 (patent application number; Japanese Patent Application No. 2010-87668) for cutting the wire 11 that has passed through the nozzle 51 by air pressure in addition to the nozzle 51, and the wire 11. A gripping device 60 is provided that grips the wire 11 by the gripping piece 60 a and prohibits the movement of the wire 11 passing through the nozzle 51.

  The cutter device 59 is attached to the support plate 54 via an air cylinder 59a that is driven by a command from a controller (not shown). With this air cylinder 59 a, the cutter device 59 is configured to be movable between a cutting position where the cutter teeth 59 b cut the wire 11 and a standby position where it is separated from the wire 11. As a result, the cutter device 59 and the gripping device 60 move with the nozzle 51 and can be controlled by a controller (not shown).

  On the other hand, the tension device 53 can apply tension to the fed wire 11 and pull back the wire 11.

  The tension device 53 in this embodiment includes a casing 61 provided on the gantry 19 and a drum 62 and a tension bar 63 provided on a side surface of the casing 61 in the Y-axis direction. The wire 11 is wound around the drum 62, and a feed control motor 64 for feeding the wire 11 by rotating the drum 62 is provided inside the casing 61. The wire 11 fed from the drum 62 is provided at the tip of the tension bar 63. Guided to guide 63a. The wire 11 guided to the wire guide 63a is wired so as to penetrate the nozzle 51 from the wire guide 63a.

  The tension bar 63 is rotatable in the X-axis direction with the rotation shaft 63b at the base end as a fulcrum. The rotation angle of the rotation shaft 63b is detected by a potentiometer 65 serving as a rotation angle detection means housed in the casing 61 and attached to the rotation shaft 63b. The detection output of the potentiometer 65 is input to a controller (not shown), and the control output from the controller is connected to the feeding control motor 64.

  Further, one end of a spring 66, which is an elastic member serving as a biasing means for applying a biasing force in the rotation direction of the tension bar 63, is attached to a predetermined position between the rotation shaft 63b of the tension bar 63 and the wire guide 63a. It is attached via a bracket 63c. The tension bar 63 is given an elastic force according to the rotation angle by a spring 66 which is an elastic member. The other end of the spring 66 is fixed to the moving member 67. The moving member 67 is screwed into a male screw 68a of a tension adjusting screw 68, and is configured to be movable and adjustable according to the rotation of the male screw 68a. Thus, the fixed position of the other end of the spring 66 can be displaced, and the tension of the wire 11 applied by the tension bar 63 can be adjusted.

  A controller (not shown) is configured to control the feed control motor 64 so that the rotation angle detected by the potentiometer 65 serving as a rotation angle detection means becomes a predetermined angle. Accordingly, in this tension device 53, tension is applied to the wire 11 through the tension bar 63 by the spring 66, and the drum 62 is rotated so that the tension bar 63 is at a predetermined angle, whereby a predetermined amount of the wire 11 is fed out. Is done. Therefore, the tension of the wire 11 is maintained at a predetermined value.

  As shown in FIGS. 5 and 7, heating means for heating the wire 11 wound around the core 22 to melt or soften the fusion layer is provided on the gantry 19 below the core 22. .

  The heating means in this embodiment is a hot air generator 71 that heats and fuses the wire 11 wound around the winding core 22 constituting the winding device 21. The hot air generator 71 is mounted on the gantry 19 so that the hot air outlet 71 a faces the core 22.

  The hot air generator 71 is mounted on the gantry 19 via an actuator 72 that can move the hot air generator 71 in the Y-axis direction. The actuator 72 is fixed to the gantry 19 with its housing 72d extended in the Y-axis direction, and a movable base 72c is provided in the housing 72d so as to be movable. A male screw 72b that is screwed into the movable base 72c is provided in the housing 72d, and a control output of a controller (not shown) is connected to the motor 72a that rotationally drives the male screw 72b. The actuator 72 is configured so that the hot air generator 71 is positioned below the core 22 in response to a command from a controller (not shown), and the hot air generator 71 blows the hot air toward the core 22 from the outlet 71a. Is done.

  As shown in FIG. 1, the non-flat coil manufacturing apparatus 20 according to the present invention forms a flat coil 12 by pressing a flat coil 12 (FIG. 13) made of a wire 11 wound around a winding core 22. A molding die 73 is provided.

  As shown in FIG. 10, the molding die 73 is formed by bending a pair of opposing short sides 12 b and 12 b (FIG. 16A) of a flat coil 12 having a square shape, thereby bending the short sides 12 b and 12 b. A pair of semicircular portions 73a and 73a to be engaged, and an engaging portion 73b that is sandwiched between the pair of semicircular portions 73a and 73a and can enter the concave strip 22d that is an engaged portion formed on the core 22 Have. Since the engaging portion 73b has a rectangular parallelepiped shape and can enter the concave strip 22d, the length L2 of the engaging portion 73b between the pair of semicircular portions 73a and 73a is equal to that of the pair of convex strips 22c and 22c. It is formed substantially the same as or slightly shorter than the length L1 (FIG. 11), and the width d2 of the engaging portion 73b is formed slightly smaller than the distance d1 (FIG. 11) between the pair of ridges 22c, 22c.

  As shown in FIG. 1, the mold 73 is provided on a movable table 74, and the non-flat coil manufacturing apparatus 20 includes a moving means 78 that moves the mold 73 together with the movable table 74.

  As shown in FIG. 3, the moving means 78 is formed between the molding position where the molding die 73 is located at the end edge of the core 22 and the standby position shown in FIG. 1 apart from the end edge of the core 22. The mold 73 is moved. Since the molding die 73 is provided on the movable table 74, the movable table 74 is provided on the gantry 19 so as to be movable in three axial directions via a moving means.

  As shown in FIG. 4, the moving means 78 in this embodiment is configured by a combination of X-axis, Y-axis, and Z-axis direction expansion / contraction actuators 79 to 81. Since the moving means 78 has the same structure as the nozzle moving mechanism 52 described above, repeated description is omitted. Further, the movable table 74 is provided with a cutter device 76 for cutting the wire 11 by air pressure, and the moving means 78 is configured to be able to move the cutter device 76 together with the movable table 74.

  As shown in FIG. 14, the cutter device 76 is configured to be capable of cutting the winding starting wire 11 extending from the binding pin 24 c provided on the outer periphery of the second rotating body 24 to the winding core 22.

  As shown in FIG. 15, the non-flat coil manufacturing apparatus 20 of the present invention extracts a flat coil 12 made of a wire 11 wound around a winding core 22 from the winding core 22 and presses it against a forming die 73 at a forming position. Coil extraction molding means 90 is provided.

  The coil extracting and forming means 90 in this embodiment includes a second ejecting rod 91 provided on the second rotating body 24 so as to be able to appear and retract. The second protruding rod 91 is a rod-shaped member that protrudes from the second rotating body 24 toward the molding die 73 at the molding position, and in this embodiment, is the four corners of the winding core 22, and the second rotating body A case is shown in which four second protruding rods 91 are provided so as to be movable in 24 axial directions.

  On the outer periphery of the second rotating body 24, second operation pins 92 for projecting the four second protruding rods 91 toward the mold 73 are provided on both sides extending in the diameter direction. As shown in FIG. 12, the second rotating body 24 has the tip of the four second protruding rods 91 rotated in the second rotation state with the second operation pin 92 retracted in a direction away from the first rotating body 23. It is configured to be flush with one end face of the body 24 and project the pair of protrusions 22c, 22c on the core 22 by an amount corresponding to the thickness of the flat coil 12 to be obtained from the one end face. Is done.

  On the other hand, as shown in FIG. 15, when the second rotary body 24 moves the second operation pin 92 forward in the direction of the first rotary body 23, that is, in the direction of the mold 73, the four second sticks 91 are moved. It is comprised so that it may protrude toward the shaping | molding die 73 direction. On the contrary, the core 22 provided on the second rotating body 24 seems to immerse the core 22 in the second rotating body 24 when the second operating pin 92 is moved forward in the direction of the molding die 73. Configured.

  As shown in FIGS. 5 and 7, a second moving device 93 that moves the second operation pin 92 in the Y-axis direction is provided on the second support wall 36. The second mobile unit 93 is provided with a second horizontal fluid pressure cylinder 94 fixed to the upper part of the first support wall 26 by extending a rod 94a in the Y-axis direction, and a vertical plate 95 at the protruding end of the rod 94a. The second vertical fluid pressure cylinder 96 is provided. The second vertical fluid pressure cylinder 96 is attached to the vertical plate 95 with the retracting rod 96a facing downward, and a second operating piece 97 is provided on the rod 96a.

  In the second operation piece 97, a concave groove 97a (FIGS. 7 and 15) into which the second operation pin 92 protruding radially from the outer periphery of the second rotating body 24 enters is formed at the lower end. Therefore, when the rod 96a of the second vertical fluid pressure cylinder 96 is protruded and the second operation piece 97 is moved downward, the second operation pin 92 enters the concave groove 97a and engages with the second operation piece 97. (FIG. 15), when the second horizontal fluid pressure cylinder 94 projects the rod 94a in that state, the second ejecting rod 91 projects from the end edge of the second rotating body 24 as shown in FIG. When the wire 11 is wound around the winding core 22 to form the flat coil 12, the flat coil 12 is extracted from the winding core 22 and pressed against the forming die 73 at the forming position.

  On the other hand, when the second horizontal fluid pressure cylinder 94 immerses the rod 94a and returns the second operation piece 97, the protruding end of the second protruding rod 91 is flush with the end surface of the second rotating body 24, and When the rod 96 a of the second vertical fluid pressure cylinder 96 is retracted, the second operation piece 97 is lifted and detached from the second operation pin 92, and the second operation pin 92 is prevented from interfering with the second operation piece 97. The second rotating body 24 is configured to allow free rotation.

  Next, the manufacturing method of the non-flat coil of this invention using the said manufacturing apparatus is demonstrated.

  The method for producing a non-flat coil according to the present invention is characterized in that the wire 11 having a fusion layer formed on the outer peripheral surface is wound around the core 22 while being heated, and the obtained flat coil 12 is formed before cooling. And Therefore, the manufacturing method of the present invention comprises a winding process and a molding process. In this embodiment, the flat coil 12 is formed by pressing the flat coil 12 extracted from the core 22 with the molding die 73 positioned at the edge of the core 22 as it is. . Below, each process is explained in full detail.

<Winding process>
In this step, the wire 11 having the fusion layer formed on the outer peripheral surface is wound around the core 22 while being heated. In the detailed procedure, first, as shown in FIG. 7, as the preparation of the winding, in the first rotating body 23, the retracting rod 31 a of the first fluid pressure cylinder 31 is inserted and the first operating piece is inserted. 32, and the protruding end of the first protruding rod 29 is flush with the end surface of the first rotating body 23 as shown in FIG.

  Further, in the second rotating body 24, the second operation pin 92 is retracted in a direction away from the first rotating body 23, and as shown in FIG. 9, the tips of the four second protruding rods 91 are rotated in the second direction. While being flush with one end face of the body 24, the pair of ridges 22c, 22c in the core 22 are protruded by an amount corresponding to the thickness of the flat coil 12 to be obtained from the one end face.

  In this state, as shown in FIG. 2, the second rotating body 24 is brought close to the first rotating body 23 by the interval variable mechanism 41, and the protruding end of the winding core 22 protruding from one end edge of the second rotating body 24 is moved to the first position. It is made to contact | abut to the end surface of the one rotary body 23. FIG. This completes the preparation of the winding.

  Thereafter, in the actual winding, the wire 11 is gripped by the gripping piece 60a of the gripping device 60, and the nozzle 51 is moved by the nozzle moving mechanism 52 in a state where the wire 11 is projected from the nozzle 51. As shown in FIG. 4, the end of the wire 11 is entangled with the pin 24c.

  In this way, after the end of the wire 11 is entangled with the pin 24c, the gripping device 60 eliminates the gripping of the wire 11 by the gripping piece 60a as shown in FIG. 2, and the wire from the wire feeder 50 is removed. 11 feeds are allowed.

  Then, as shown in FIG. 12, the nozzle 51 is moved by the nozzle moving mechanism 52, the wire 11 extending from the binding pin 24c is drawn between the first rotating body 23 and the second rotating body 24, and the winding is wound. Do.

  In the winding, the first rotating body 23 and the second rotating body 24 are rotated in the same direction in synchronization with the winding core 22, and the wire 11 fed from the wire feeding machine 50 is wound around the winding core 22. Specifically, the servo motors 27 and 38 in the winding device are synchronously rotated in the same direction, and the first and second rotating bodies 23 and 24 are moved in the same direction together with the core 22 as shown in FIG. Rotate at the same speed.

  In this way, the flat wire 12 is formed by winding the wire 11 fed from the wire feeder 50 through the nozzle 51 onto the core 22 sandwiched between the first and second rotating bodies 23 and 24. Here, the wire 11 fed from the wire feeder 50 is wound around the core 22 sandwiched between the first and second rotating bodies 23 and 24 to form the flat coil 12, so that the first and second rotations are performed. By setting the gap between the bodies 23 and 24 to a desired thickness, the flat coil 12 having a desired thickness can be obtained.

  In the formation of the flat coil 12, a certain tension is applied to the wire 11 fed from the wire feeder 50 by the wire feeder 50.

  As shown in FIG. 6, the tension is applied by a tension device 53 in the wire feeder 50, and the tension device 53 applies tension to the wire 11 through a tension bar 63 by a spring 66. Therefore, in the formation of the flat coil 12, the tension of the wire 11 is maintained at a predetermined value, and it is possible to prevent a difference in the degree of close contact between the wire 11 in the flat coil 12.

  Further, in this winding process, the hot air generator 71 as a heating means heats the wire 11 by blowing hot air from the blowout port 71a toward the core 22 in accordance with a command from a controller (not shown). The adhesion of the fusion layer formed on the outer surface of the wire 11 is increased, and the wires 11 wound to form the flat coil 12 are adhered to each other.

  After the flat coil 12 is obtained, the wire 11 is gripped by the gripping piece 60a of the gripping device 60 to prevent the wire 11 from being fed from the wire feeder 50, and then the cutter device 59 (FIG. 6). ) Is moved to the cutting position by the air cylinder 59a, and the wire 11 extending from the flat coil 12 to the wire feeder 50 is cut.

<Molding process>
In this step, the obtained flat coil 12 is formed before cooling. For molding, first, the second rotating body 24 is moved away from the first rotating body 23 that is not moved together with the core 22 by the interval variable mechanism 41 (FIG. 7) and is sandwiched between the first and second rotating bodies 23 and 24. Increase the interval. At that time, the first fluid pressure cylinder 31 (FIG. 7) is used so that the flat coil 12 made of the wire 11 wound around the winding core 22 remains on the first rotating body 23 side and is not extracted from the winding core 22. ) Is protruded, and the first protruding rod 29 provided on the first rotating body 23 is protruded from the end face of the first rotating body 23 with which the flat coil 12 is in close contact.

  With the protruding first protruding rod 29, the flat coil 12 is pushed toward the second rotating body 24, and the flat coil 12 is left around the winding core 22, so that the first rotating body 23 to the second rotating body. 24 is moved away together with the winding core 22.

  After the interval between the first and second rotating bodies 23 and 24 is increased in this way, the cutter unit 76 is then moved together with the movable base 74 by the moving unit 78, and the cutter unit 76 As shown in FIG. 14, the wire 11 at the beginning of the winding extending from the binding pin 24 c provided on the outer periphery of the second rotating body 24 to the winding core 22 is cut.

  Thereafter, as shown in FIG. 3, the mold 78 is moved together with the movable base 74 by the moving means 78, and the mold 73 is moved to the molding position located at the edge of the core 22. And as shown in FIG. 14, the engaging part 73b of the shaping | molding die 73 is made to approach into the to-be-engaged part 22d which consists of a ditch | groove formed between a pair of convex strips 22c and 22c in the core 22, and the shaping | molding is carried out. The mold 73 is accurately positioned at a predetermined position on the edge of the core 22.

  Thereafter, the rod 96a of the second vertical fluid pressure cylinder 96 (FIG. 7) is projected to lower the second operation piece 97 as indicated by the solid line arrow in FIG. 15, and the second operation pin 92 enters the concave groove 97a. In this state, the second horizontal fluid pressure cylinder 94 (FIG. 7) projects the rod 94a.

  Then, as shown in FIG. 15, the flat coil 12 formed by causing the second protruding rod 91 to protrude from the end edge of the second rotating body 24 and winding the wire 11 around the winding core 22 is removed from the winding core 22. It is extracted and pressed against the molding die 73 at the molding position. At the same time, the core 22 is immersed in the second rotating body 24, and the flat coil 12 is reliably extracted from the core 22.

  In this way, the pair of opposed short sides 12b and 12b (FIG. 16A) of the flat coil 12 forming a square shape are pressed against the semicircular portions 73a and 73a of the mold 73, and the pair of short sides 12b and 12b. Is curved along the semicircular portions 73a and 73a.

  Then, the pair of opposed long sides 12a and 12a (FIG. 16A) of the flat coil 12 remain, and the pair of opposed short sides 12b and 12b of the flat coil 12 are curved, so that FIG. As shown, the pair of long sides 12a, 12a becomes a pair of straight portions 10a, 10a facing each other at a predetermined interval, and the pair of short sides 12b, 12b are curved to form the pair of straight portions 10a, 10a, The arc portions 10b and 10b connect the end edges of 10a in an arc shape. As a result, a so-called saddle-shaped non-flat coil 10 can be obtained.

  In the present invention, the flat coil 12 is formed before cooling to obtain the non-flat coil 10. That is, until the flat coil 12 is formed and the non-flat coil 10 having a bowl shape is formed, the fusion layer of the wire 11 forming the flat coil 12 is not solidified.

  Therefore, in the previous winding process, even if heating is stopped by the hot air generator 71 as a heating means when the flat coil 12 is formed, the fusion layer of the wire 11 is formed until the non-flat coil 10 is formed. If the flat coil 12 is not formed, the hot air blowing from the hot air generator 71, which is a heating means, is stopped when the flat coil 12 is formed, and the heating of the wire 11 is stopped.

  On the other hand, if heating of the wire 11 by the hot air generator 71 is stopped, if the fused layer of the wire 11 immediately solidifies, the heating means forms the non-flat coil 10 from the winding process. Until the wire 11 is heated by the hot air generator 71 until the non-flat coil 10 is formed, the hot air generator 71 stops the heating. Then, the fusion layer formed on the outer surface of the wire 11 is solidified and the wires 11 are bonded to each other, and the shape of the non-flat coil 10 forming the saddle shape obtained by molding is maintained.

  In this way, in the present invention, the flat coil 12 obtained by winding around the core 22 while being heated is molded before cooling, so the fusion layer is melted in each step during winding and molding. Alternatively, the time for obtaining the non-flat coil 10 having a desired shape can be remarkably shortened as compared with the conventional softening.

  And the non-plate-shaped coil 10 which formed the desired shape obtained by the shaping | molding completes the adhering between each wire 11 by completing cooling after shaping | molding. For this reason, each wire 11 which comprises the non-plate-shaped coil 10 obtained by shaping | molding mutually adheres, and the shape of the obtained non-plate-shaped coil 10 is maintained reliably after that. As a result, in the non-flat coil manufacturing apparatus and non-flat coil manufacturing method of the present invention, the non-flat coil 10 can be manufactured relatively quickly.

  Further, the flat coil 12 is immediately formed by pressing the flat coil 12 extracted from the core 22 as it is positioned on the edge of the core 22 and pressing the flat coil 12 as it is, so that the mold for the core 22 is formed. By always keeping the position 73 constant, the flat coil 12 is not misaligned during molding. For this reason, the non-flat coil 10 obtained by the present invention always has a desired shape.

  Thereafter, the non-planar coil 10 whose shape is fixed by solidifying the fusion layer of the wire 11 is then moved from the molding position together with the molding die 73 by the moving means 78. The moving means 78 moves the non-flat coil 10 to the discharge position and discharges it. The molding die 73 that has discharged the non-flat coil 10 returns to the standby position in FIG. 1 again and waits until the next molding step. As a result, the production of a series of non-flat coil 10 is terminated, and the production of the next non-flat coil 10 is started again from the winding step described above. If it does in this way, it will become possible to obtain the non-plate-like coil 10 which has a desired shape continuously.

  In particular, the engaged portion 22d is formed at the edge of the winding core 22, and the engaging portion 73b that can be engaged with the engaged portion 22d at the forming position is formed in the forming die 73. Therefore, the forming die 73 at the forming position is formed. The position with respect to the core 22 is surely constant. For this reason, the non-plate-like coil 10 obtained by the present invention always has a desired shape, and the present invention makes it possible to mass-produce the non-plate-like coil 10 having a uniform shape.

  In the above-described embodiment, the nozzle moving mechanism 52 and the movable table moving means 78 configured by a combination of the X-axis, Y-axis, and Z-axis direction extendable actuators have been described. The structure is not limited to this, and other types may be used as long as the nozzle 51 and the movable table 74 are movable in the three-axis directions with respect to the gantry 19.

  Moreover, in embodiment mentioned above, the case where the blowing of the hot air from the hot air generator 71 was stopped and the heating of the wire 11 was stopped was demonstrated. However, since the hot air generator 71 which is a heating means is attached so as to be movable in the Y-axis direction via the actuator 72, the hot air generator 71 is moved by the actuator 71, and the hot air blown off is not blown to the wire 11. In this way, heating of the wire 11 may be stopped.

  Further, in the above-described embodiment, the wire 11 having a round cross section has been described. However, the wire 11 may be a so-called square wire having a square cross section.

DESCRIPTION OF SYMBOLS 10 Non-plate-shaped coil 11 Wire material 12 Flat coil 20 Non-plate-shaped coil manufacturing apparatus 21 Winding device 22 Core 22d Engagement part 50 Wire material feeding machine 71 Hot air generator (heating means)
73 Molding die 73b Engaging portion 78 Moving means 90 Coil extraction molding means

Claims (4)

A wire rod feeding machine (50) for feeding a wire rod (11) having a fusion layer formed on the outer peripheral surface with a constant tension, and a wire rod (11) fed from the wire rod feeding machine (50) is a core (22). A winding device (21) to obtain a flat coil (12) by winding the wire (11), and the wire (11) wound around the core (22) to heat or melt or soften the fusion layer In a non-flat coil manufacturing apparatus comprising heating means (71),
A molding die (73) for molding the flat coil (12) by pressing the flat coil (12);
Moving means (78) for moving the molding die (73) between a molding position located at an edge of the core (22) and a standby position spaced from the edge of the core (22);
Coil extraction molding means (90) for extracting the flat coil (12) made of the wire (11) wound around the winding core (22) from the winding core (22) and pressing it against the molding die (73) at the molding position. And a non-flat coil manufacturing apparatus.   An engaged portion (22d) is formed at the edge of the core (22), and an engaging portion (73b) that can be engaged with the engaged portion (22d) at the molding position is formed in the mold (73). The apparatus for producing a non-flat coil according to claim 1.   A non-planar coil characterized in that the wire (11) having a fusion layer formed on the outer peripheral surface is wound around a core (22) while being heated, and the obtained flat coil (12) is formed before cooling. Manufacturing method.   When forming the flat coil (12), the forming die (73) is positioned at the edge of the core (22), and the flat coil (12) is extracted from the core (22), and at the same time, the forming die (73). The manufacturing method of the non-plate-shaped coil of Claim 3 performed by pressing on.

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